(Another) Starter Contacts Removal Thread!

[96LTDrus]

Just did this, this write-up was a big help! I was into it about 4 hours total all said and done with plain old hand tools. Used the breaker bar with a 6 point impact socket on the exhaust bracket bolts and the starter bolts. That starter is a bear to manipulate with

A few photos on the writeup seem to no longer be hosted, or at least they didn't load on my PC?

Anyhow, thanks a bunch for the DIY! This is prime example of why these now 20 year old trucks are still so sustainable, the breadth and depth of knowledge by the vast community of users, and the helpful write-ups that they post!

 

[One Sick Puppy]

Well, my runner finally won't start. I've been able to get away with a couple tries every now and then, but all I get is clicks now. Gonna pull the starter today.

Question, if the starter turns a little tiny bit, but not enough, does that still mean the contacts can be bad? I bump it with a hammer a couple times and it turned a little once or twice, but not enough to get the engine going. I'm a bit concerned that there is electrical contact but it can't turn for another reason?

 

[NorthernRunner]

Question, if the starter turns a little tiny bit, but not enough, does that still mean the contacts can be bad? I bump it with a hammer a couple times and it turned a little once or twice, but not enough to get the engine going. I'm a bit concerned that there is electrical contact but it can't turn for another reason?

Mine did the same thing. It would click 30-40 times, occasionally would turn a little, then click a bunch, then finally turn over properly. So yes, your contacts can still be bad even if the starter turns a tiny bit.

I changed the contacts in mine and it starts, but the starter sometimes still stays engaged and you can hear that awful grinding noise briefly, which most likely means the starter solenoid isn't working properly. Just something of which to be aware after you've changed your contacts.

 

[One Sick Puppy]

Well, got the starter out pretty easy with the help of the OP's tutorial. (Thank you!) Cracked it open and looks like the the larger contact is almost completely worn out. Going to replace all 3 (including plunger contact) since it's open. Hopefully this will cure my problem.

 

[NorthernRunner]

I blasted mine all out with electrical contact cleaner, too, to clean up all the mess in there. If you haven't already put yours back in, that is.

 

[One Sick Puppy]

Good call. I'll do that, too.

 

[CoMarc]

Hey all!

There's not a day goes by I don't miss my 4Runner, but I had to move on. Maybe someday I'll get back in one. For now, I've updated the images on this thread so more people can see what I did way back then. Hopefully these last longer!

Enjoy, and glad so many are getting good use out of this! Thanks to all that have contributed more to this thread with helpful tips!

 

[TheDurk]

Hey all!

There's not a day goes by I don't miss my 4Runner, but I had to move on. Maybe someday I'll get back in one. For now, I've updated the images on this thread so more people can see what I did way back then. Hopefully these last longer!

Enjoy, and glad so many are getting good use out of this! Thanks to all that have contributed more to this thread with helpful tips!

Love to see this. Too many good DIY's have died because the OP's didn't maintain the hosting of the photos.

Thank you.

 

[dirteater4]

Did the contact and plunger swap last Thursday night. Funny enough, the transmission dip stick gave me the most trouble! The exhaust bracket that everyone else is referencing, wasn't even on my truck. I had zero problems with the bolts, as my leaking valve cover gaskets had soaked everything below that line with oil (changed those 3 months ago, all good and no leaks since). I did have to work on the starter in the wheel well because I have the larger 1.8kw. The issues "clicking" only started 5 days prior to me having to do the repair. Many people say they can get months out of the starter by bumping it. No such luck for me. I ordered the parts online (5 days before failure) thinking I had plenty of time. I ended up having to pick up an entire starter up from O'reilly's and took what I needed from it. BTW, the plunger in the rebuilt one I bought was better than the stock. Contact plate was thicker and the return springs were beefier. The parts I ordered should be here tomorrow. I'll then put the parts back on the O'reilly "loaner" and return it.

 

[TheDurk]

Did the contact and plunger swap last Thursday night. Funny enough, the transmission dip stick gave me the most trouble! The exhaust bracket that everyone else is referencing, wasn't even on my truck. I had zero problems with the bolts, as my leaking valve cover gaskets had soaked everything below that line with oil (changed those 3 months ago, all good and no leaks since). I did have to work on the starter in the wheel well because I have the larger 1.8kw. The issues "clicking" only started 5 days prior to me having to do the repair. Many people say they can get months out of the starter by bumping it. No such luck for me. I ordered the parts online (5 days before failure) thinking I had plenty of time. I ended up having to pick up an entire starter up from O'reilly's and took what I needed from it. BTW, the plunger in the rebuilt one I bought was better than the stock. Contact plate was thicker and the return springs were beefier. The parts I ordered should be here tomorrow. I'll then put the parts back on the O'reilly "loaner" and return it.

As far as that goes, I bet you are a Cali. I didn't have it either on my '99 with Cali. exhaust.

 

[dirteater4]

Colorado. Truck was purchased new in Virginia, then went to Georgia (I bought it there).

 

[runner4play]

CoMark, as others have said, Thank you! I'll be going for a complete swap only bc my plunger has been getting stuck and making horrid metallic noises for a couple months now, but your photos and write up have been a great help. I will post back my findings on the job.

Oh.. and at least the original did last 278k

PS: I'm new to posting on the board instead of just searching... those in CO lets wrench and wheel.

 

[runner4play]

Sooo... my starter finally blew up... almost literally. I knew i was taking too long to replace it, but I just hadn't made time. I went to leave a few days ago.. and Click Bang! Pics attached of the destroyed starter sorry they suck a little.

I also learned the reason why some of us are probably having an easier time getting the starters in and out. It seems there is a difference in the body size for different models. I purchased a reman 1.8kw starter and it was almost a full inch shorter in length than the 1.8kw that was originally in the truck.

At 280k miles, I believe this was the original starter so kudos to it. Upon removal the plunger was stuck cocked to the side in side the bell housing. It wouldn't budge. I ended up removing the spark plugs and rolling the motor back a little to get it to come out.


Sadly .... I made a horrrrrrrible rookie mistake when it was all done. checked everything for tightness, cleaned up, and was ready to hear her crank again.... some how I forgot that I had moved the crank with a 1/2 in driver.... still hanging on the crank bolt.... imagine nightmares (( all sorts of noise, I shut it down quick and the crank bolt had come loose and fallen out with the driver... The stock fan also destroyed.


2 days later I'm still working on getting the crank bolt torqued back to spec. A real headache for sure. As I always have hated the manual fan... well now I have an excuse to to Efan.

I'm gonna check a couple shops near my house tomorrow to see if any of them have the special tool to hold the crank... so far everything I have tried either bent the device i used or the bolts i used to hold it in.....

Very bad lesson that I supposed I needed a reminder about, but hopefully fixed asap. More mods coming soon!

 

[poser]

My runner has started doing this too. Great thread! Though I'm still just considering replacing the starter.

 

[truedef]

My runner has started doing this too. Great thread! Though I'm still just considering replacing the starter.

I just ordered the contacts and new plunger off ebay for $10 vs 60+ on a new starter

 

[4Runner4TW]

Just replaced the starter contact on mine. It was a ***** to get out of their. You do need to bend the brake line just a bit. I only replaced the large contact; it was all but gone.

I did run into one problem. The little rubber vent tube that is on the starter snapped off in my hands. This happen to anyone else? Hopefully no water gets into it I guess...

 

[poser]

I just ordered the contacts and new plunger off ebay for $10 vs 60+ on a new starter

Yeah it's way more expensive, but if I just replace the contacts, I'm putting a 15 yr old starter back in.


Sent from my iPhone using Tapatalk

 

[mtbtim]

Here's a video I did for my starter repair:

<iframe width="560" height="315" src="https://www.youtube.com/embed/WV1t5-wcoOI" frameborder="0" allowfullscreen></iframe>

 

[Soulbro101]

Thank you!
Just finished same project on my 2000 4Rnr.
Your pics and descriptions helped IMMENSELY!
2 things to add from my experience:
#1- my rig does not have that exhaust bracket w the 3 bolts so i got to skip step 6 (maybe cuz mine's a 2 whl drive? Or a 2000?)
#2- my starter pretty much fell right out after i removed the two mounting bolts, so i was able to take it apart outside the vehicle (which was nice)
Also want to add that like Zcruiser, i replaced the plunger as well, and i replaced both contacts since i was in there anyway, even tho only the one looked obviously grooved.
Still saved over $400, and feel stoked to have done it all myself!
Ready to take on a more involved project!!
Thanks again!!

 

[Soulbro101]

Yep, i broke off both of 'em ha!
I bought 2 new ones from dealer but only one came in w the contacts and plunger so i wrapped electrical tape around the starter and over the vent hole and used an exacto knife to pierce a slit in the tape. Worked fine til the other vent got delivered...